CPI T02KO User manual

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INSTALLATION
&
OPERATION
MANUAL
250W Ka-Band TWT Amplifier
For Use With Model Numbers . . .
T02KO
T03KO
Service Center Headquarters and Design Center
West Coast Operations
811 Hansen Way
Palo Alto, CA 94303
Manufacturing
East Coast Operations
45 River Drive
Georgetown, ON Canada L7G 2J4

PROPRIETARY INFORMATION
The design and other information contained in this document are provided solely for the
purposes of operating and maintaining CPI equipment. Except for rights expressly granted by
contract, all such information is the exclusive property of CPI Satcom Division. This document
may not be duplicated, in whole or in part, or be used for manufacture without written
permission of CPI, Satcom Division.
Copyright @ 2007 by Communications & Power Industries. All rights reserved.
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Table of Contents
CHAPTER Safety ........................................................................................................................................S-1
S.1 Introduction......................................................................................................................................S-1
S.2 High Voltage Equipment.................................................................................................................S-1
S.2.1 Personnel Operating Guidelines................................................................................................S-1
S.2.2 When is Voltage "High"?...........................................................................................................S-2
S.2.3 General High Voltage Guidelines..............................................................................................S-2
S.3 Microwave Radiation.......................................................................................................................S-5
S.3.1 Personnel Operating Guidelines................................................................................................S-5
S.3.2 Microwave Discussion...............................................................................................................S-5
S.3.3 General Microwave Guidelines .................................................................................................S-6
S.4 Physical Safety..................................................................................................................................S-7
S.4.1 Lifting Heavy Objects.................................................................................................................S-7
S.4.2 Extending Rack Slides................................................................................................................S-7
CHAPTER 1 Introduction..........................................................................................................................1-1
1.1 Overview...........................................................................................................................................1-1
1.2 Optional Features.............................................................................................................................1-3
1.3 About This Manual..........................................................................................................................1-3
1.4 Conventions......................................................................................................................................1-4
1.4.1 Notes and Cautions....................................................................................................................1-4
1.4.2 Warnings....................................................................................................................................1-5
1.4.3 Text Conventions........................................................................................................................1-5
CHAPTER 2 Unpacking And Installation.................................................................................................2-1
2.1 Overview...........................................................................................................................................2-1
2.2 Pre-Inspection ..................................................................................................................................2-1
2.3 Unpacking.........................................................................................................................................2-1
2.4 Installation........................................................................................................................................2-1
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INSTALLATION AND OPERATION MANUAL
2.4.1
Amplifier Installation.................................................................................................................2-2
2.4.2 Cooling Considerations .............................................................................................................2-2
2.4.3 Electrical Power Connections ...................................................................................................2-3
2.4.3.1 Prime Power (J1)....................................................................................................................2-3
2.4.3.2 Grounding ..............................................................................................................................2-3
2.4.4 Remote Control Interface (J6) ...................................................................................................2-4
2.4.5 Switch Interface Connector (J5) ................................................................................................2-5
2.4.6 RF Coaxial Cable Connections (J4)..........................................................................................2-5
2.4.7 RF Input Waveguide Flange Connection (J3) ...........................................................................2-6
2.4.8 RF Output Waveguide Flange Connection (J8).........................................................................2-6
CHAPTER 3 Initial Power On And Checkout.........................................................................................3-1
3.1 Overview...........................................................................................................................................3-1
3.2 Front Panel Controls and Indicators .............................................................................................3-2
3.3 Optional RCU Controls and Indicators.........................................................................................3-4
3.3.1 Multi-Drop Operation................................................................................................................3-4
3.3.3.1 Amplifier Address Assignment..............................................................................................3-4
3.3.1.2 Operational Summary of the Remote Control Unit (RCU)....................................................3-5
3.3.2 Control Keys ..............................................................................................................................3-7
3.3.3 LED Group and Display...........................................................................................................3-8
3.4 Operation with PC Computer and Setup & Remote Control Software....................................3-11
3.5 Operation with Ethernet ...............................................................................................................3-12
3.6 First Time Pre-Power Procedure..................................................................................................3-12
3.7 Power-On Sequence.......................................................................................................................3-13
3.7.1 Initial Check, High Voltage OFF.............................................................................................3-13
3.7.1.1 Check Factory Set Values via a Computer ..........................................................................3-14
3.7.1.2 Check Factory Set Values via RCU.....................................................................................3-14
3.7.2 Initial Check, High Voltage ON...............................................................................................3-18
3.8 Verify RF Output...........................................................................................................................3-19
3.9 Setup for Operational Service.......................................................................................................3-20
CHAPTER 4 External Interfaces...............................................................................................................4-1

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4.1 Overview...........................................................................................................................................4-1
4.1.1 Control Mode Hierarchy............................................................................................................4-1
4.2 Serial Interface.................................................................................................................................4-1
4.2.1 Interface Configuration..............................................................................................................4-1
4.3 RF Switch Interface (J5)..................................................................................................................4-2
4.3.1 Relay Definitions........................................................................................................................4-2
4.4 Ethernet Interface............................................................................................................................4-6
4.4.1 IP Setup......................................................................................................................................4-7
4.4.2 Web Interface.............................................................................................................................4-9
4.4.3 Configuring Email ...................................................................................................................4-10
4.4.4 Changing the Login..................................................................................................................4-11
4.4.5 Amplifier Information ..............................................................................................................4-12
4.4.6 Download / Upload Files using FTP.......................................................................................4-13
4.4.7 Firmware updates....................................................................................................................4-14
4.4.8 LAN Interface Port Numbers ...................................................................................................4-15
4.5 JAVA CIF Remote Program.........................................................................................................4-16
Java JRE ..................................................................................................................................................4-16
4.5.1 Running CIF Remote: ..............................................................................................................4-16
4.5.2 Meters ......................................................................................................................................4-18
4.5.3 Setup.........................................................................................................................................4-19
4.5.4 Settings.....................................................................................................................................4-20
4.5.5 Engineering..............................................................................................................................4-21
4.5.6 Configuration...........................................................................................................................4-22
4.5.7 Meter Log.................................................................................................................................4-23
4.5.8 Switch System...........................................................................................................................4-24
CHAPTER 5 Normal Operation ................................................................................................................5-1
5.1 General..............................................................................................................................................5-1
5.2 Overview of Operation ....................................................................................................................5-2
5.3 Normal Operating Procedures........................................................................................................5-2
5.3.1 LOCAL Mode Operation............................................................................................................5-2
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5.3.2 Remote Control Mode, Computer Control.................................................................................5-3
5.4 Shutdown..........................................................................................................................................5-3
5.4.1 Normal Shutdown.......................................................................................................................5-3
5.4.2 Prime Power Interrupts .............................................................................................................5-4
5.5 Making Routine Safety Checks.......................................................................................................5-4
5.6 Description of Amplifier States.......................................................................................................5-4
5.6.1 Post ............................................................................................................................................5-5
5.6.2 Heater Time Delay (HTD) .........................................................................................................5-5
5.6.3 Standby State..............................................................................................................................5-5
5.6.4 Beam On Sequence.....................................................................................................................5-6
5.6.5 Transmit State............................................................................................................................5-6
5.6.6 Beam Off Sequence ....................................................................................................................5-6
5.6.7 Fault State..................................................................................................................................5-6
5.6.7.1 Auto Fault Recycle Mode Rules............................................................................................5-6
5.6.7.2 Meter log...............................................................................................................................5-7
CHAPTER 6 Operator Maintenance.........................................................................................................6-1
6.1 Introduction......................................................................................................................................6-1
6.2 Preventive Maintenance Tasks.......................................................................................................6-1
6.2.1 Visual Inspection........................................................................................................................6-2
6.2.2 Air System Maintenance.............................................................................................................6-3
6.3 Other Preventive Maintenance Tasks............................................................................................6-4
6.4 Customer Service .............................................................................................................................6-4
CHAPTER 7 Drawings................................................................................................................................7-1
APPENDIX A Warranty And Support Information...............................................................................A-1
APPENDIX B.............................................................................................................................................. B-1
B.1 Introduction..................................................................................................................................... B-2
B.2 Installation....................................................................................................................................... B-2
B.2.1 Connecting to the Amplifier(s)...................................................................................................B-2
B.2.2 Meters Window ..........................................................................................................................B-4
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B.2.3 Settings Window.........................................................................................................................B-5
B.2.3.1 General.............................................................................................................................. B-5
B.2.3.2 Configuration.................................................................................................................... B-7
B.2.3.3 Engineering....................................................................................................................... B-7
B.2.3.4 CIF .................................................................................................................................... B-8
B.2.4 Meter Log...................................................................................................................................B-8
B.2.4.1 Auto Update...................................................................................................................... B-9
B.2.4.2 Auto Log Time.................................................................................................................. B-9
B.2.4.3 Search................................................................................................................................B-9
B.2.4.4 Save File............................................................................................................................ B-9
B.2.5 Switch Systems .........................................................................................................................B-11
B.2.5.1 Switch Configuration Diagrams...................................................................................... B-12
B.2.6 Alerts........................................................................................................................................B-15
B.2.6.1 Media Player................................................................................................................... B-15
B.2.6.2 Restore Window.............................................................................................................. B-16
B.2.6.3 Confirmation................................................................................................................... B-16
B.2.7 Tuning Screen Setup.................................................................................................................B-16
B.2.7.1 Millitron.......................................................................................................................... B-16
B.3 Troubleshooting.................................................................................................................................. B-17
B.3.1 Communication........................................................................................................................B-17
APPENDIX C Replaceable Parts ..............................................................................................................C-1
APPENDIX D Optional Linearizer...........................................................................................................D-1
D-1 Optional Linearizer ........................................................................................................................D-1
APPENDIX E 250w ODU Functional Trees............................................................................................. E-1
APPENDIX F Optional Internal 1:1 Switch Controller..........................................................................F-1
F.1 Optional Internal 1:1 Switch Controller........................................................................................F-1
F.2 Drawing List.....................................................................................................................................F-3
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List of Figures
FIGURE 1-1. KA-BAND TWTA (FRONT VIEW)______________________________________________1-2
FIGURE 1-2. TYPICAL KA-BAND TWTA RF DIAGRAM________________________________________1-3
FIGURE 2-1. KA-BAND TWTA CONNECTOR LOCATIONS _____________________________________2-4
FIGURE 2-2 RS-232 CABLES __________________________________________________________2-5
FIGURE2-3 KA-BAND TWTA REAR PANEL ______________________________________________2-7
FIGURE 3-1 AMPLIFIER FRONT PANEL CONTROLS AND INDICATORS ___________________________3-2
FIGURE 3-2. REMOTE CONTROL UNIT FRONT AND REAR PANELS _______________________________3-4
FIGURE 3-3. REMOTE CONTROL UNIT CONTROL KEYS________________________________________3-8
FIGURE 3-4. LED AND DISPLAY GROUP ___________________________________________________3-9
FIGURE 3-5. REMOTE CONTROL UNIT MENU TREE___________________________________________3-9
FIGURE 3-6-A. REMOTE CONTROL UNIT MENU TREE ________________________________________3-10
FIGURE 3-6-B. REMOTE CONTROL UNIT MENU TREE ________________________________________3-11
FIGURE 3-7. ETHERNET OPTION_________________________________________________________3-12
FIGURE B-1 STARTUP SCREENS_________________________________________________________ B-2
FIGURE B-2 CONFIGURATION SCREEN / AMPLIFIERS 1-5 TAB _________________________________ B-3
FIGURE B-2A CONFIGURATION SCREEN / INTERFACE TAB ____________________________________ B-3
FIGURE B-3 TYPICAL METER SCREEN____________________________________________________ B-4
FIGURE B-4 TYPICAL SETTING SCREEN / GENERAL TAB _____________________________________ B-6
FIGURE B-4A CONFIGURATION TAB _____________________________________________________ B-7
FIGURE B-4B ENGINEERING TAB ________________________________________________________ B-7
FIGURE B-4C CIF TAB ________________________________________________________________ B-8
FIGURE B-5 TYPICAL METER LOG SCREEN________________________________________________ B-8
FIGURE B-6 SAVE LOG FILE SCREENS___________________________________________________ B-10
FIGURE B-7 TYPICAL SWITCH DIAGRAM SCREEN__________________________________________ B-11
FIGURE B-8A 1:1A FIGURE B-8B 1:1B _____________________________________ B-12
FIGURE B-8C 1:1C __________________________________________________________________ B-12
FIGURE B-8D 1:1D-P ________________________________________________________________ B-12
FIGURE B-8E 1:1E __________________________________________________________________ B-13
FIGURE B-8F 1:1E-P_________________________________________________________________ B-13
FIGURE B-8G 1:2A __________________________________________________________________ B-13
FIGURE B-8H 1:2B __________________________________________________________________ B-14
FIGURE B-8I 1:2C___________________________________________________________________ B-14
FIGURE B-8 ALERTS TAB_____________________________________________________________ B-15
FIGURE B-9 MILLITRON CHANNEL TUNING/CHANGING SCREENS _____________________________ B-16
FIGURE B-11 ADDRESS SCANNER SCREEN _______________________________________________ B-17
FIGURE F-1. INTERCONNECT DIAGRAM (OPTIONAL SW CONTROLLER)___________________________F-2
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List of Tables
TABLE 1-1. KA-BAND TWT AMPLIFIERS _________________________________________________1-1
TABLE 3-1 KA-BAND TWTA FRONT PANEL CONTROLS AND INDICATORS______________________3-3
TABLE 3-2. FRONT PANEL CONTROL KEYS_________________________________________________3-7
TABLE 3-3 LED GROUP AND DISPLAY DESCRIPTION_______________________________________3-8
TABLE 3-4. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 120W CW/250W PEAK_________3-15
TABLE 3-5. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 175W CW / 250W PEAK________3-16
TABLE 3-6. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 250W/275W CW______________3-17
TABLE 4-1. RF SWITCH PIN ASSIGNMENT (J5): 1:1 SWITCH OPTION _____________________________4-5
TABLE 4-2. DEFAULT CONFIGURATION-ETHERNET INTERFACE OPTION __________________________4-7
TABLE 4-3. ETHERNET INTERFACE PORT NUMBERS _________________________________________4-15
TABLE 6-1 PREVENTIVE MAINTENANCE PERFORMED BY OPERATORS _________________________6-2
TABLE 6-2 PREVENTIVE MAINTENANCE PERFORMED BY TECHNICIAN _________________________6-2
TABLE 7-1 DRAWINGS ______________________________________________________________7-1
TABLE C-1 REPLACEABLE PARTS _____________________________________________________ C-1
TABLE F-1. KA BAND TWTA DRAWINGS__________________________________________________F-3
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